Production of biodiesel, cellulosic sugars, and peptides from the simultaneous esterification and alcoholysis/hydrolysis of materials with oil-containing substituents including phospholipids and cellulosic and peptidic content

ABSTRACT

The present invention relates to a method for producing fatty acid alkyl esters as well as cellulosic simplified sugars, shortened protein polymers, amino acids, or combination thereof resulting from the simultaneous esterification and hydrolysis, alcoholysis, or both of algae and other oil containing materials containing free fatty acids (FFA), glycerides, or combination thereof as well as polysaccharides, cellulose, hemicellulose, lignocellulose, protein polymers, or combination thereof in presences of an alcohol and an acid catalyst.

CROSS REFERENCE TO RELATED APPLICATIONS

The present patent application is a continuation of U.S. application Ser. No. 12/061,038 filed Apr. 2, 2008, which claims the benefit of U.S. provisional patent application Ser. No. 60/921,327 filed on Apr. 2, 2007. The contents of these prior applications are hereby incorporated by reference and in their entirety.

FIELD OF THE INVENTION

The present invention pertains to the esterification of free fatty acids (FFAs) and glycerides with alcohol in the presence of an acid catalyst to form fatty acid alkyl esters. The present invention further pertains to the simultaneous esterification and hydrolysis/alcoholysis of a feedstock containing free fatty acids (FFAs), glycerides, or both as well as cellulosic material, proteins, or both in the presence of an alcohol and acid catalyst to form fatty acid alkyl esters as well as cleaved cellulosic material, shorter peptides, amino acids, or combination thereof.

BACKGROUND OF THE INVENTION

Over the past three decades interest in the reduction of air pollution, and in the development of domestic energy sources, has triggered research in many countries on the development of non-petroleum fuels for internal combustion engines. For compression ignition (diesel) engines, it has been shown that the simple alcohol esters of fatty acids (biodiesel) are acceptable alternative diesel fuels. Biodiesel has a higher oxygen content than petroleum diesel, and therefore reduces emissions of particulate matter, hydrocarbons, and carbon monoxide, while also reducing sulfur emissions due to a low sulfur content.

For spark ignition (gasoline) engines, ethanol, produced by fermentation of simple sugars generated from corn starch, can be blended with petroleum gasoline to substitute petroleum content with renewable content fuel, reduce dependence on foreign oil, reduce carbon dioxide emissions, and improve octane in the blended fuel. Since both ethanol and biodiesel are made from agricultural materials, which are produced via photosynthetic carbon fixation (e.g., by plants and by animals that consume plants), the combustion of biodiesel and ethanol does not contribute to net atmospheric carbon levels.

Initial efforts at the production, testing, and use of biodiesel employed refined edible vegetable oils (e.g. soybean oil, canola oil), used cooking oils (e.g. spent fryer oils) and animal fats (e.g., beef tallow) as feedstocks for fuel synthesis (Krawczyk, T., INFORM, 7: 800-815 (1996); Peterson, C. L., et al., Applied Engineering in Agriculture, 13: 71-79 (1997); Holmberg, W. C., and J. E. Peeples, Biodiesel: A Technology, Performance, and Regulatory Overview, National Soy Diesel Development Board, Jefferson City, Mo. (1994)).

Simple alkali-catalyzed transesterification technology (Freedman, B., et al., J. Am. Oil Chem. Soc., 61(10): 1638-1643 (1984)) is efficient at esterifying the acylglycerol-linked fatty acids of such feedstocks and is employed in making these fuels. More recently, methods have been developed to produce fatty acid methyl esters (FAME) from cheaper, less highly refined lipid feedstocks such as spent restaurant grease (Mittelbach, M., and P. Tritthart, J. Am. Oil Chem. Soc., 65(7):1185-1187 (1988); Graboski, M. S., et al., The Effect of Biodiesel Composition on Engine Emissions from a DDC Series 60 Diesel Engine, Final Report to USDOE/National Renewable Energy Laboratory, Contract No. ACG-8-17106-02 (2000); Haas, M. J., et al., Enzymatic Approaches to the Production of Biodiesel Fuels, in Kuo, T. M. and Gardner, H. W. (Eds.), Lipid Biotechnology, Marcel Dekker, Inc., New York, (2002), pp. 587-598).

In addition to acylglycerols, less highly refined lipid feedstocks can contain substantial levels of free fatty acids (FFA) and other nonglyceride materials. Biodiesel synthesis from these feedstocks can be accomplished by conventional alkaline catalysis, which then requires an excess of alkali since the FFA (which are not esterified by this method) are converted to their alkali salts. These alkali salts can cause difficulties during product washing due to their ready action as emulsifiers. Ultimately, the alkali salts are removed and discarded. This approach thus involves a loss of potential product, increases catalyst expenses, and can entail a disposal cost.

Further, with higher FFA levels, i.e. typically in excess of 2%, a general approach is to utilize an acid esterification step, since at higher FFA values the extent of soap formation with a single stage, transesterification process is excessive and renders the process uneconomical and potentially unworkable. To handle the higher FFA content, a two step process involving first acid-catalyzed esterification of the free fatty acids and then alkali-catalyzed transesterification of glyceride-linked fatty acids can be employed to achieve conversion of mixed, heterogeneous feedstocks (Canakci, M., and J. Van Gerpen, Biodiesel Production from Oils and Fats with High Free Fatty Acids, Abstracts of the 92.sup.nd American Oil Chemists' Society Annual Meeting & Expo, p. S74 (2001); U.S. Pat. Nos. 2,383,601; 2,494,366; 4,695,411; 4,698,186; 4,164,506). However, these methods can require multiple acid-catalyzed esterification steps to reduce the concentration of free fatty acids to acceptably low levels. In addition, high separation efficiency is required between the two stages to minimize the potential for acid catalyst transfer into the base catalyst section.

The feedstocks used for current biodiesel production are conventional commodity materials, thus they have other established markets which basically set the minimum commodity prices. As a result, the bulk of the biodiesel production cost relates to the feedstock cost. While there are a number of established process technologies in the biodiesel industry, as a result of the feedstock cost being such a high factor (i.e. 75% to 80%) there is a surprisingly small difference between the various processes in overall operational costs (due to this feedstock factor).

The production of ethanol for fuel use is well established and the growth in this industry over the past 2 decades has been significant. Fermentation is an (obviously) old process going back literally thousands of years to early wine and beer making. The basic techniques remain the same, however in the modern ethanol production process highly efficient enzymes and yeasts have been developed to provide for more efficient conversion of the fermentable materials. Further, the process technology associated with fuel grade ethanol production has also advanced over the years, e.g. energy recovery, so that current technology has a high degree of efficiency.

The primary feedstocks for current commercial ethanol production are corn (primarily in the United States) and sugar (especially in Brazil). As in the biodiesel case, these materials are “conventional” agricultural commodities and have historically had various markets associated with them, i.e. food sources and the like. It is also apparent that since these are commodity products, there are various non-fuel market pressures that dictate price. As such, for ethanol production, as in the case of biodiesel, the feedstock represents the vast majority of the operating cost (i.e. as much as 80%).

For both the biodiesel and ethanol fuel markets and for the large-scale expansion of the renewable fuels industries, it is apparent that development of a potentially large scale, lower cost feedstock source would be advantageous. Recently, significant advances have been made in carbon dioxide sequestering technology (aquatic species program reference, NREL, GFT, a U.S. company) using various species of algae to provide photosynthetic carbon fixation. This technology has tremendous value when applied to industrial sources of carbon dioxide such as; coal fired power generation, natural gas fired power generation, petroleum fired power generation, industrial gas generation, cement manufacturing, industrial fermentation, as well as various additional industries that are significant emitters of carbon dioxide. The algae resulting from the photosynthetic carbon fixation represents an opportunity for the production of transportation fuels as well as various value added chemical products. The volume of algae produced per acre, in a designed pond or “farming” system, is estimated at between 200,000 pounds to 600,000 pounds per year of algae on a dry basis; and is substantially greater, in terms of oil content and fermentable material content, than the volume of soybeans or corn produced per acre at 2,500 pounds to 10,000 lbs per year. The volume of algae produced using the above method allows for a far greater production density versus corn or soybeans with a relatively small geographic footprint. In addition, the algae selected comprise free fatty acids (FFA), triglycerides, polysaccharides, cellulose, hemicellulose and/or lignocellulose. However, the economical processing of the selected algae provides significant challenges for conventional biofuel processing techniques.

For the algae scenario, a significant degree of pretreatment of the sludge is required to prepare the material for the more traditional solvent extraction methods to recover the contained oil. This front-end pretreatment would then need to be combined with multi-stage esterification, (for free fatty acid esterification) and transesterification (for triglyceride conversion), and a completely separate process would be required for acid hydrolysis of the lipid depleted algae pulp to produce monosaccharides, disaccharides, trisaccharides or polysaccharides for production of ethanol by fermentation. This series of processing steps would add significant cost to the resulting materials to be produced from algae. Therefore, there is a need for further development of simplified processing routes for the production of fatty acid alkyl esters (i.e. FAME), monosaccharides, disaccharides, trisaccharides or polysaccharides in a simplified, direct process.

In addition, the current growth in biofuel production from food commodities is generating a substantial increase in co-products such as corn distillers grains, sorghum distillers grains, and rice bran meal. These co-products have underutilized value from the cellulosic content (45-55% by mass) and oil content (7-22% by mass) which represent an opportunity to increase the supply of biofuels to market by simply increasing the processing efficiency of current methods.

Again, the interest in cellulosic feeds for ethanol has increased considerably over the past several years, however some of the same issues apply to this source as to feeds such as algae. For example, with cellulosic feeds the typical approaches include enzyme treatment followed by yeasts which convert the cellulosic materials to sugars and subsequent alcohol, but has little effect on any contained oil content. For example distillers grains have both cellulosic content as well as contained oil values, both of which could be useful for conversion to biofuels.

Thus, there remains a significant need in the art to develop a simple and efficient method for the production of biofuels and ethanol from renewable energy sources.

SUMMARY OF THE INVENTION

The present invention relates to a method for making fatty acid alkyl esters by (a) combining a feedstock with an alcohol and an acid catalyst and (b) reacting the combination at a pH in the range of 0 to 5, at a temperature in the range of 140° C. to 260° C., and at a pressure that is sufficient to prevent boiling of the alcohol during the reaction, wherein the feedstock comprises (a) free fatty acids (FFAs), glycerides, or both and (b) cellulosic material, proteins, or both and wherein the reaction products comprise (a) fatty acid alkyl esters and (b) cleaved cellulosic material, shortened proteins, amino acids, or a combination thereof.

The following reactions can occur in the above method: (a) the direct esterification of FFAs into fatty acid alkyl esters, (b) the transesterification of glycerides into fatty acid alkyl esters, (c) the hydrolysis, alcoholysis, or both of the cellulosic material into cleaved cellulosic material, and (d) the hydrolysis, alcoholysis, or both of protein into shorter peptides, amino acids, or both.

The present invention is further directed to the product from the reaction of the feedstock with the alcohol and acid catalyst.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides a schematic of the reaction of the feedstock (110) with the alcohol (120) in the presence of the acid catalyst (130) and optionally in the presence of water (160) and fatty acid alkyl esters (170) in a pressurized reactor (140) to products (150).

FIG. 2 shows the detailed process concept used for the simultaneous production of biodiesel and ethanol from the algae and/or feedstocks, such as agricultural by-product material. The overall approach is shown for multiple feedstocks. If dry material is received, then the front end drying system would not necessarily be required.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a method for producing fatty acid alkyl esters as well as cellulosic simple sugars, shortened protein peptide polymers, and amino acids involving esterifying and performing hydrolysis, alcoholysis, or both on a material containing free fatty acids, glycerides, or both as well as polysaccharides, cellulose, hemicellulose, lignocellulose, protein, or combination thereof with an alcohol and an acid catalyst.

Prior to the present invention, the conversion of biomass into biofuel and ethanol was a time-consuming and multi-step procedure that was both economically inefficient and wasteful. Additionally, conventional methods are inhibited by the presence of water. In contrast, a fast, single-step, and efficient method for the conversion of biomass into biofuel and sugars to produce ethanol can be performed in the presence of water. FIG. 1 illustrates a method of the present invention in which feedstock (110) is reacted with alcohol (120) in the presence of an acid catalyst (130) and optionally in the presence of water (160) and fatty acid alkyl esters (170) in a pressurized reactor to yield products (150).

The feedstock for this process can be, for example, algae (e.g., fresh or salt water algae, prokaryotic algae), dried distillers grains (DDG) from, e.g., corn or sorghum, rice bran, jatropha seed, palm seed, vegetable oil seeds (e.g., soybean, canola), eukaryota, protozoa, phytoplankton, cyanobacteria, bacteria, corn ethanol fermentation residuals, or other oil-containing material that may also contain potentially fermentable cellulosic material (e.g., polysaccharides, cellulose, hemicellulose, and lignocellulose), protein, or both. The oils of the feed stock can include FFAs, monoglycerides, diglycerides, triglycerides, or combination thereof. The feedstock can also be a combination of different oil-containing materials.

The feedstock can contain from about 0 wt % to about 100 wt % FFA, e.g., from about 5 wt % to about 10 wt % FFA. The feedstock can contain about 0 wt % to about 100 wt % glycerides, e.g., from about 10 wt % to about 50 wt % glycerides. The feedstock can contain from about 0 wt % to about 50 wt % cellulosic material (preferable less than about 30 or 40 wt %, but at least about 1, 5, 10, or 15 wt %). The feedstock can contain from about 0 wt % to about 50 wt % protein (preferable less than about 30 wt %, but at least about 1, 5, 10, or 15 wt %). Each of the amounts for the feedstock components listed above is based on the dry weight of the feedstock.

The feedstock can be unextracted meaning that it has not been purified to remove certain components (e.g., water, cellulosic material, proteins, or mixtures thereof). For example, the feedstock can contain FFAs, glycerides, at least about 10 wt % cellulosic material, and at least about 10 wt % proteins, wherein both weight percentages are based on the total dry weight of the feedstock. The feedstock can also be purified (e.g., a soapstock or crude vegetable oil). The feedstock can contain husks, shells, or other materials that are grown by the feedstock source other than the feedstock. Materials that contain both oil and cellulosic components lead to attractive renewable fuel alternatives. The feedstock, prior to reaction, can be dried as, e.g., discussed below. The feedstock can be ground to reduce its particle size prior to reaction.

For purposes of this description, algae is used as the feedstock, however those skilled in the art would understand that other feedstock can be used. Also, the overall process is, as indicated, applicable to the other feedstocks with adjustments to the process configuration, e.g. if a dry distillers grain or dry rice bran is used as a feedstock, then the drying step would not be required.

In addition, with other feedstocks, there may be some variations in the acid esterification chemistry such that alternate co-products are formed in the reaction. For example, with a high cellulosic feed (e.g., at least about 1, 5, 10, or 15 wt % but less than about 30, 40, or 50 wt % based on the dry weight of the feedstock) there may be further conversion of that component to derivatized sugar compounds such as methyl or ethyl glucosides. For example, when a solution of glucose in methyl alcohol is saturated with hydrochloric acid a crystallizable compound having the formula C₆H₁₁O₆CH₃, is formed.

A similar reaction takes place with all of the alcohols which are capable of dissolving glucose, such as methanol, ethanol, propanol, butanol, and their isomers, and the compounds formed correspond to natural glucosides. The sugar entering into the reaction need not necessarily be glucose, so that a number of such artificial alcohol-derivatized sugars can be prepared. The hydrochloric acid of the reaction to produce derivatized sugars can also be replaced by another acid such as H₅SO₄. These derivatized sugars, when boiled with dilute acid, react with water and are decomposed into the sugar and alcohol. In addition, further derivatization at the higher ranges of temperatures and pressures can lead to valuable dehydration products from the sugars such as 5-(hydroxymethyl)furfural, levulinic acid, formic acid, and esters thereof. The categorization of each feedstock may be necessary to determine the best process splits and optimal end-products.

The alcohol for the invention can be, for example, methanol, ethanol, propanol, butanol, isopropyl alcohol, sec-butanol, t-butanol, benzyl alcohol or combination thereof. From a practical standpoint, and for general fuel and potential downstream chemical considerations, alcohols containing from 1 to 5 carbons would be preferred, however, there may be specific situations and conditions wherein higher alcohols could be used. Testing with a specific alcohol would readily determine the amenability of a particular alcohol. Again, for purposes of this discussion, methanol is used as the alcohol, however those skilled in the art would understand that other alcohols can be used. For example, in a combined system that produces both ethanol and biodiesel, it is potentially attractive to use some of the produced ethanol as the alcohol reactant.

The acid catalyst for the invention can be, for example, an inorganic acid (e.g., sulfuric acid, anhydrous hydrochloric acid, anhydrous nitric acid, boron trifloride, and phosphoric acid), an organic acid (e.g. organic sulfonic acid), a solid phase catalyst (e.g., Envirocat™ EPZG, natural kaolinite clay, B₂O₃/ZrO₂, sulfated SnO₂, and zeolites), or combination thereof.

For the purposes of this description, sulfuric acid is used as the acid catalyst, however those skilled in the art would understand that other acid catalysts can be used.

In the process (see FIG. 2), the algae sludge (1), produced via various algae growing processes, e.g. the recovery of CO₂ from a power plant or other major CO₂ producing stack gases, or other feedstock is first dried in a flash drying system wherein a recycled stream of superheated steam is used to dry the feedstock. The water content of the feedstock after drying can be about 0 wt % to about 10 wt % of the dry weight of the feedstock, from about 3 wt % to about 10 wt % of the dry weight of the feedstock, or from about 3 wt % to about 5 wt % dry weight of the feedstock. The resulting steam, from the wet material, is purged from the system (2) and used for downstream process heat.

Systems that are useful for this step include spin flash dryers; spray dryers; loop dryers; and the like. The main criterion for dryer choice is that the system can be operated at elevated pressure to allow for production of reasonably usable purge steam. A pressure of 10 psig to 30 psig is preferred with 15 psig to 20 psig most preferred. Drying can be carried out at atmospheric pressure, however, in this case the resulting vapor from the dryer cannot be reused for downstream steam uses. Pressurized drying enhances the overall economics of the process, but is not essential for practice of the technique, i.e. atmospheric drying is acceptable, recognizing the economics of the system.

The dried algae (3) or other feedstock can be ground to reduce its particle size and is then transferred to the Direct Esterification Reactor system wherein the feedstock is mixed with the selected alcohol (e.g., methanol) (5), and acid catalyst (4). The amount of alcohol can vary, but would typically be sufficient to allow for a slurry mixture. This typically provides sufficient excess of alcohol for the reaction noting that 3 moles of alcohol are required for reaction with 1 mole of triglycerides to form 3 moles of fatty acid alkyl esters and 1 mole of alcohol is required for reaction with 1 mole of FFAs to form 1 mole of fatty acid alkyl esters. As a minimum, the amount of alcohol should be in about a 15% molar excess of the contained oil. Preferably, the alcohol should be in an amount from about 50 mol % to about 600 mol % of the contained oil (i.e., glycerides and FFAs), preferably from about 50 mol % to about 320 mol % of the contained oil and most preferably from about 200 mol % to about 300 mol % of the contained oil. On a weight percentage basis, the contained oil will require about 11% to 12% by weight of methanol to form the methyl ester. Higher alcohols would require a higher weight percentage of alcohol. For practical operation, the amount of alcohol would normally be in the range of about 50 wt % to 300 wt % of the dry feedstock and preferably in the range of about 100 wt % to about 200 wt % of the dry feedstock.

To reduce the amount of alcohol used, and subsequently reduce the downstream demethylation requirements, a portion of the produced biodiesel (8A) can be recycled to the reactor to provide liquid for slurry formation. The amount of fatty acid alkyl ester (i.e., biodiesel) added to the reaction can be in an amount from about 50 wt % to about 300 wt %, preferably from about 100 wt % to about 200 wt %, and most preferably from about 125 wt % to about 150 wt % of the dry weight of the feedstock.

This will allow for introduction of alcohol in amounts sufficient to provide the amount required for the reaction, plus some excess to ensure complete reaction. In this case, the amount of make-up alcohol (e.g. methanol) could be in the range of 5% to 15% by weight of the dry input feedstock.

The amount of acid catalyst can range from about 0% to about 15% by weight of the dry feedstock, preferably from about 3% to about 9% by weight of the dry feedstock, and most preferably from about 4% to about 8% by weight of the dry feedstock. The final amount of acid will depend on the composition of the feedstock, since there may be acid consuming compounds in the feed, e.g. reactive protein materials and the like. Thus the actual acid rate will depend on this factor. From a general process consideration standpoint, the key process factor is the amount of “free catalyst” in the system, i.e. free acid after consideration of any components in the feedstock that will consume acid. Preferably the amount of free acid remaining in the mixture is such that the resulting pH of the slurry is in the range of about 0 to about 5, and most preferably in the range of about 2 to about 3.

To shift the yield towards cellulosic sugar formation as well as ester formation, and away from the acid consuming peptides polymer breakdown, the acid content can be eliminated or significantly reduced. In the absence or reduction of acid catalyst (e.g., in the range from about 0.01 to 1 wt % based on the dry weight of the feedstock), the temperature of the reaction is increased to a range of about 240° C. to about 300° C., preferably about 240° C. to about 270° C. and the pressure of the reaction is increased to a range of about 1,000-2800 psi, preferably from about 1,100-1,900 psi, to promote cellulose sugar polymer breakdown, derivatized sugar formation, and triglyceride polymer breakdown for biodiesel (i.e., fatty acid alkyl ester) formation.

The reaction mixture before reaction can also contain water in an amount of at least about 3 wt % of the dry weight of the feedstock, at least about 5 wt % of the dry weight of the feedstock, or at least about 10 wt % of the dry weight of the feedstock.

The pH of the mixture can be from about 0 to about 5, preferably from about 1 to about 4, and most preferably from about 2 to about 3

The mixture is then reacted at elevated temperature, e.g. in the range of about 140° C. to about 300° C., in the range of about 160° C. to about 275° C., or in the range of about 175° C. to about 275° C. A pressure reactor system is used that will allow for the elevated temperature and keep the alcohol from boiling. The pressure of reactor operation is slightly in excess of the vapor pressure of the alcohol of choice at the selected operating temperature (e.g. 20 psig over the vapor pressure). Typical pressures range from about 150 psig to about 650 psig, preferably from about 200 psig to about 500 psig, and most preferably from about 300 psig to about 400 psig. Pressures significantly in excess of the alcohol vapor pressure are not required in the process approach.

The reactor system can be batch or continuous. There are several conventional pressure vessel systems available that will operate in batch and continuous modes and the process lends itself to the “conventional” methods for this stage.

In addition, a continuous pipe-type reactor can be used to carry out the reaction. The reactor is a pipe with sufficient residence time to allow for the reaction to complete and is operated under the target pressure and temperature range. The pipe allows for reasonable reaction to occur with minimized vessel complexity.

The reaction can be carried out for a period of about 5 minutes to 120 minutes and the reaction time can depend on the selected reaction system and operating temperature. In a conventional stirred tank reactor, the reaction time can be in the range of 60 to 90 minutes for a batch reactor. At higher temperatures, and corresponding pressures, the reaction time can be reduced.

In the reaction, the alcoholysis, hydrolysis or both, of the cellulosic material occur first. The alcohol, water or both act as solvents for the acid catalyst, which attacks the sugar polymer linkages to form cellulosic simple sugars (i.e., smaller sugar polymers or monosaccharides). The acid catalyst is not selective and will simultaneously perform esterification as well as perform alcoholysis, hydrolysis, or both on the complex protein polymers and shorten said protein polymers as well as produce amino acids.

The free fatty acids (FFA) are the second materials to convert to methyl (or other alcohol) ester, with the co-production of water. Since the reaction is carried out at higher temperatures, after the conversion of the FFA, the triglyceride (lipid) content coverts to the methyl (or other alcohol) ester, with co-production of glycerin. The protein polymers require the longest residence time in the system if complete polymer linkage break down is sought. Not to be bound by any theory, this description of the reaction sequence is a general supposition.

A key finding and outcome of this acid esterification approach is that during the course of the biodiesel formation reactions, the presence of the acid also results in the alcoholysis, hydrolysis, or both of the cellulosic material and prepares the solid phase for subsequent fermentation. Acid hydrolysis of cellulosic materials has been discussed in relation to wood waste materials, switch grass, corn stovers, corn cobs, and the like. Typically this hydrolysis is carried out in an aqueous system where a single reaction is sought. In addition, depending on the feedstock, there may be further conversion of the sugar fractions to derivatized or dehydrated materials such as methyl glucosides, ethyl glucosides and 5-(Hydroxymethyl)furfural, etc. The extent will depend on the acid concentration, reaction time, and reaction temperature for the particular feedstock being processed.

The reaction product slurry (6) typically consists of the algae pulp (containing cleaved cellulosic material, shortened peptides, and amino acids), crude biodiesel, excess alcohol, catalyst, water and glycerin. The resulting fatty acid alkyl esters will be in the range of 10-50 wt % of the product slurry. The resulting peptides/amino acids will be in the range of 0-50 wt % of the product slurry. The resulting cleaved cellulosic materials will be in the range of 0-50 wt % of the product slurry. The reaction slurry is transferred to a Liquid/Solid Separation system. In this step, the liquid fraction is separated from the solids portion. Separation can be carried out using any number of standard separation techniques, such as filtration, centrifugation, combinations of each approach, and the like. Slight washing of the solids, in the separation device, can be carried out with a small amount of the alcohol (9A) recovered for recycle. The spent wash would then be added into the crude biodiesel fraction.

The washed solids (7) are then sent to a demethylation step wherein the methanol (or other alcohol) is removed from the material via heating. Steam, from the aforementioned drying system can be used for this step. The recovered alcohol (14) is transferred to the Methanol (Alcohol) Recovery System. The solids fraction (20) is transferred to the ethanol production portion of the process.

The crude biodiesel liquid from the separation (8) is then sent to a Biodiesel Demethylation/Bottoms Separation system. In this process step, the liquid is first demethylated, i.e. alcohol removal, and the vaporized alcohol (9) sent to the Methanol (Alcohol) Recovery System. In the recovery system, the alcohol is distilled to eliminate traces of moisture then returned (15) to the reaction system for reuse.

When the alcohol is removed from the crude biodiesel, the co-products, i.e. water and glycerin separate from the biodiesel fraction. The catalyst reports to the aqueous/glycerin phase. This two phase system is then treated in a separation system, e.g. settling, centrifugation, and the like. The separated water/glycerin/catalyst is referred to as the “bottoms” fraction. This material (11) is transferred to a storage tank for subsequent disposition. Depending on the feedstock, the bottoms from the demethylation/bottoms separation step may contain high levels of protein-bearing materials. In this case, the protein-rich fraction (11A) can be sent to a separate surge and (if desirable) downstream processes for further separation of the protein fraction from the remainder of the material.

The demethylated biodiesel (10) is then sent to the Biodiesel Distillation unit. In this step, the biodiesel is heated to about 340° F. to 360° F. and subject to a high vacuum in the range of 750 mm to 755 mm Hg (vacuum). Under these conditions, the biodiesel fraction vaporizes and separates from the various lower volatility impurities in the liquid.

The biodiesel vapor is then condensed using conventional indirect heat exchangers with cooling supplied by cooling water. The condensed biodiesel (12) is the transferred to biodiesel storage tanks where the material is analyzed and confirmed for shipment.

The demethylated solids (20) are transferred to a Solids Neutralization/Separation system. In this stage, the pulp is mixed with water (22) and a caustic solution (21), e.g. sodium hydroxide, potassium hydroxide, etc. Ideally potassium hydroxide is used since the resulting potassium salt, i.e. potassium sulfate, is a feed source for the downstream fermentation process. The material is neutralized to a pH of about 5.5 to 7.0. The target pH is that which is consistent with the specific reagent used in the fermentation process.

After neutralization, the slurry can be subjected to a separation step, if required, to remove a portion of the aqueous fraction with an accompanying removal of dissolved salts. This solution (24) would be returned to the algae farms and the potassium sulfate salt used as a food make-up source for the algae material.

The neutralized pulp (23) then enters a Fermentation System wherein it is mixed with conventional fermentation reagents (25), e.g. yeasts, etc., then allowed to react in a conventional fashion. Information relative to the conventional processing approaches are available on numerous web-sites and a significant resource is the Renewable Fuels Association (available on the WorldWideWeb at rfa.org), which is the key industry trade association. The main advantage is that a potentially lower cost feedstock has now been made available that does not involve a current agricultural food source commodity but rather second generation non food materials such as algae or agricultural by-products.

In the fermentation system, the cellulosic sugars convert to ethanol, with the co-production of carbon dioxide. The CO₂ fraction would normally be vented back to the CO₂ recovery system for pick-up by the algae used in the carbon dioxide recovery system if algae is used.

The fermentation slurry (26) is then sent to a Solid/Liquid Separation system, and the non-fermented solids removed from the liquid (beer) phase. Again, conventional separation methods may be utilized, such as filters, centrifuges, and the like. The solids fraction (27) can then be used elsewhere e.g. return to the algae farms as a supplemental food source.

The fermented liquid (28) is transferred to an Evaporation System wherein the alcohol phase is evaporated from the liquid, along with some water. The aqueous fraction from the evaporator (30) is returned to the algae farm system.

The alcohol fraction (29) is next treated in a Distillation/Molecular Sieve system. In this process step, the aqueous alcohol is first distilled, to produce a nominal 95% ethanol material, then processed in a molecular sieve unit to remove the remaining water and produce a 99.5%+ethanol product (31). This operation is conventional and widely used in the current ethanol production industry.

The residual solids from the fermentation stage will contain the non-fermentable materials that may also contain significant levels of useful proteins or amino acids. This solids fraction could be combine with other animal feed products or, depending on the exact nature of the material (based on the feedstock), further processed, via drying, to produce a specialized feed product.

EXAMPLE 1 Algae Testing

The following example illustrates the basic process approach and resulting product potential for algae feedstocks. Table 1 summarizes a series of tests conducted with algae feedstocks (either fresh or salt water algae) using the process described above. The initial pH was at 0.4. The temperature was between 140-180° C. The pressure was between 200 and 500 psig. The reaction time was between 1-2 hours. The starting algae contained anywhere from 10% to 25% lipid content of which the FFA values ranged from 5% to as much as 10%. The resulting recovered biodiesel indicated that the contained oil was essentially completely converted to the methyl ester. The percent conversion of oil to fatty acid methyl ester was greater than 95%.

TABLE 1 Test 1 2 3 4 5 6 7 Dry algae (grams) 1,000 1,000 1,000 1,000 1,000 1,000 1,000 Acid catalyst (grams) 25 25 25 25 25 25 25 MeOH (grams) 1500 1400 1300 1200 1200 1200 1200 material subjected to temperature and pressure reaction conditions reactor product separated in centrifuge, centrate taken to demethylation two phases observed after demethylation, centrifuged to separate ester from starch/protein Results Dry weight pulp 550 544 555 539 553 630.5 611 Fatty Acid Methyl Ester 222 219 224 217 223 94 98 (FAME) Starch 193 191 195 189 194 225 247.5 minor amounts of material lost in handling through laboratory equipment variations from tests 1-5 and tests 6-7 represent various fresh and salt water algae. Process technique is capable of processing all algae tested into FAME and starch

A sample of the solid residue material (i.e, pulp), that contained the starch fraction was then mixed with water and neutralized to a pH of about 6.5-7. Standard ethanol processing yeast was added and the material was allowed to ferment for a period of about 5 days. A small laboratory system was used wherein the mixture was contained in a contained flask. A CO₂ discharge tube was located on top of the flask and the CO₂ was discharged, via a dip leg, into a separate flask containing water. This maintained a “water seal” on the fermentation flask and also allowed for visual observation of CO₂ bubbles, which, when they stopped, indicated fermentation completion.

After the CO₂ evolution stopped, the resulting fermentation broth was filtered to remove residual solids. The resulting liquid was heated to evaporate a mixture of ethanol and water in a single stage evaporation flask with a condenser. The condensed ethanol water phase contained about 8% ethanol. In commercial practice, the weak ethanol would be treated in a conventional evaporation/distillation/molecular sieve system (e.g. the standard approach used in the conventional ethanol production processes) to recover an anhydrous ethanol product. The techniques are well established, and again reference is made to the Renewable Fuels Association web-site.

About 50% of the contained starch converts to actual ethanol (the remainder forming CO₂). The expected ethanol recovery from the algae feedstocks would be on the order of 10% by weight of the algae. This conversion factor will depend on the potential starch content of the starting algae and can vary between various specifies of material. The recovery factors are for illustration and are no way meant to limit the scope or require a specific recovery.

EXAMPLE 2 Algae Soapstock Testing

Algae soapstock is a by-product of the conventional algae oil processing route wherein the oil, containing high levels of free fatty acids (FFA), is treated with an alkali solution to neutralize the FFA and produce a “soapstock” that consists of neutralized fatty acids. This material is separated from the aqueous salt solution and typically recovered as a “soapstock” material. A similar product is formed, in large amounts, from soybean oil treatment and is sold, at relatively low cost, for subsequent acidulation and recovery of the fatty acid values, as a free fatty acid, for use in animal feeds or other lower valued applications.

To assess the potential for soapstocks as feeds, a sample of algae soapstock was obtained and processed in a manner similar to that outlined for the algae (Example 1), with the exception that a solids/liquid separation after the esterification stage was not required. Briefly, the soapstock was initially neutralized with sulfuric acid, then methanol and additional sulfuric acid was added to provide excess acid (for catalyst). The mass of soapstock was 100 g. The mass of the initial sulfuric acid was 17 g to acidify the soap. The mass of the methanol was 200 g. The additional mass of the sulfuric acid used for the catalyst was 4 g. The initial pH was below 1. The moisture content in the feedstock was on the order of 10 wt % to 15 wt % of the weight of the feedstock, based on the indicated supplier estimates (as supplied by Advanced Bio Nutrition, Columbia, Md.). The mass was reacted for about 2 hours at about 140° C. under pressure sufficient to avoid methanol evaporation.

The reaction mass was then neutralized with lime (to eliminate any free sulfuric acid) and the material then separated via a centrifuge into an aqueous phase, containing the water, glycerin, and salt fraction, and an organic phase. The organic phase containing essentially the biodiesel fraction was then distilled to recover the ester fraction. The resulting biodiesel was analyzed and met the ASTM standards for this material. In this case there was no sugar or starch-like fraction so ethanol is not a consideration for this feedstock.

Of considerable note with this test is that the esterification was carried out in a relatively high free water environment (i.e. in excess of 10% free water), since the soapstock, as indicated, is a neutralized FFA from the oil feed. This is of significance since for the conventional biodiesel processing approaches, including the two stage processes consisting of acid esterification followed by base transesterification, water must be limited, typically to levels of less than 1% to 2% for acid esterification and less than 0.5% for the transesterification step.

EXAMPLE 3 Distillers Grain (Corn Feedstock)

Distillers grain is a major co-product from the production of ethanol using the conventional corn feedstocks. Dry distillers grain (DDG) is the material remaining after the fermentation process and contains proteins, fats, fiber, ash, and other various components. Much of this material is used in animal feed products, but its value, compared to corn, is lower.

The quantities of this material are significant. For example, a 100 million gallon/year ethanol facility using a dry corn feed would produce on the order of 660 million pound/year of DDG. In general, the DDG from corn contains about 10% to 11% fat (oil content that is potentially convertible to biodiesel) and about 45% to 50% carbohydrates (which if properly prepared could serve as a fermentation feed).

It should be noted that with preparation, the resulting sugars consist of both C6 and C5 fractions. The C6 fraction is fermentable via the use of standard yeast materials. C5 sugars will not ferment with yeasts only, and specialized enzymes have been developed that will convert C5's. In addition, there are other processes that have been developed that utilize C5 sugars to produce other (non-ethanol) products.

Significant advantages could be brought about in the biofuels industries if this feedstock could be further processed to recover additional ethanol and produce a biodiesel product as well. Incorporation of DDG treatment operations within existing ethanol plants could further enhance the potential economic attractiveness.

To assess the potential for the process to handle this feed, samples of DDG from ethanol facilities (Verasun Energy of Brookings, S. Dak. and White Energy of Dallas, Tex.) that processed both corn and sorgum feedstocks were obtained. The basic testing approach was as follows:

-   -   The DDG was mixed with methanol and sulfuric acid catalyst then         reacted at elevated temperature and pressure for about 2 hours.         Typically the temperature was maintained at about 200 deg C. The         mass of the DDG was 100 grams, the mass of the methanol was 200         grams, the mass of the sulfuric acid was 8 grams, the initial pH         was 0.5.     -   After reaction, the ester product mass was then filtered and         washed with additional alcohol to remove residual ester, sugars,         etc.     -   The solids fraction was then set aside and would be used as a         lower grade animal feed in a commercial scenario.     -   The liquid fraction was then heated to remove excess alcohol         (that would be recovered for recycle in a commercial scenario).     -   The mixture was then neutralized to convert the free sulfuric         acid to a neutral salt. Neutralizing agents can include common         alkalis, e.g. sodium hydroxide, potassium hydroxide, sodium         bicarbonate, potassium carbonate, calcium oxide, calcium         hydroxide, etc. The use of calcium is ideal since it allows for         subsequent animal feed nutrition. The liquid, containing the         esters, glycerine, derivitized sugars, amino acids and the like         was treated in an additional separation stage to remove the         ester fraction from the non-ester fraction. Several methods are         available for this including solvent extraction, with e.g.         hexane, or water dissolution (preferred) to solublize the         glycerin and sugar fraction and allow for separation of the         ester as an separate phase (i.e. liquid/liquid separation).     -   The ester fraction was then treated in a distillation system to         recover the ester as a high grade material.     -   The sugar, amino acid fraction (non-esters) was then neutralized         and, if a calcium material used, filtered to remove the         resulting calcium sulfate salt. This has the effect of reducing         the potential ash in the final amino acid.     -   With the reaction conditions employed, derivatized sugars, such         as 5-(hydroxymethyl)furfural, were formed which will allow for         potential production and recovery of other products.

For the example test, the material used was the corn DDG and contained about an 11 wt % oil fraction based on the total weight of the DDG. The above process was carried out and after separation and analysis, the resulting biodiesel fraction was about 10% by weight of the feed, indicating that essentially all of the contained oil was converted to the ester.

The ester fraction was then distilled and the recovered biodiesel analyzed for total and free glycerin, since these are the key components of successful ester production based on previous laboratory testing. The material was well below the allowable ASTM standards.

EXAMPLE 4 Rice Bran

Rice bran is another material that is a major co-product of this grain processing industry. There are significant amounts of this material produced in the U.S and especially overseas. The bulk of this material is used in various feed additives and has a relatively low value.

A sample of rice bran was processed in the same manner as that used for the DDG sample (in Example 3). The composition of the bran was somewhat similar to that of the DDG with respect to carbohydrate content (i.e. potentially fermentable) but the oil content was somewhat higher (typically 18 wt % or so).

After ester recovery, the material was distilled and the biodiesel analyzed. Again the material was well within specifications. Also, the amount of biodiesel produced was in line with the expected value based on the oil content. Several tests have indicated that the expected biodiesel production is about the same (volume-wise) as the oil content in the starting feedstock.

The remaining treated carbohydrate fraction would then normally be subject to fermentation since the composition at this stage is similar to the material obtained in the DDG processing.

The disclosed process has been tested with a variety of oil/starch-containing feedstocks as well as high soap materials. The examples are shown for illustration purposes only and in no way restrict the scope as to the potential feedstocks that are suitable for this approach.

The present invention is not to be limited in scope by the specific embodiments described herein. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description. Such modifications are intended to fall within the scope of the appended claims.

All references cited herein, including all patents, published patent applications, and published scientific articles, are incorporated by reference in their entireties for all purposes. 

1. A method for making fatty acid alkyl esters, the method comprising: (a) combining a feedstock with an alcohol and an acid catalyst, wherein the feedstock comprises (i) free fatty acids (FFAs), glycerides, or both and (ii) cellulosic material, proteins, or both; and (b) reacting the feedstock and the alcohol, at a temperature in the range of 140.degree. C. to 300.degree. C., and at a pressure that is sufficient to prevent boiling of the alcohol during the reaction to (i) generate fatty acid alkyl esters, (ii) cleave the cellulosic material, if present, and (iii) shorten the proteins, if proteins are present.
 2. The method of claim 1, wherein the feedstock contains at least 10 wt % cellulosic material based on the dry weight of the feedstock.
 3. The method of claim 1, wherein the feedstock contains at least 10 wt % proteins based on the dry weight of the feedstock.
 4. The method of claim 1, wherein the water content of the combination before reaction is at least 3 wt % of the dry weight of the feedstock.
 5. The method of claim 1, further comprising adding a fatty acid alkyl ester to the combination before reacting.
 6. The method of claim 1, further comprising drying the feedstock prior to combining the feedstock with the alcohol and acid catalyst.
 7. The method of claim 6, wherein the water content of the feedstock after drying is in the range of about 3 wt % to about 5 wt % of the dry weight of the feedstock.
 8. The method according to claim 1, wherein said feedstock is algae, dried distillers grain (DDG), or a mixture thereof.
 9. The method of claim 1, wherein the alcohol is methanol or ethanol.
 10. The method of claim 1, wherein the alcohol is in an amount from 50% to 320% molar excess of the contained oil in the feedstock.
 11. The method according to claim 1, wherein the acid catalyst is sulfuric acid.
 12. The method of claim 1, wherein the acid catalyst is in an amount from 4 wt % to 8 wt % of the dry weight of the feedstock.
 13. The method of claim 1, wherein the temperature is in the range of 175.degree. C. to 275.degree. C.
 14. The method of claim 1, wherein the pressure is at least 20 psig above the vapor pressure of the alcohol at the temperature of the reaction.
 15. A method for making fatty acid alkyl esters, the method comprising: (a) combining a feedstock with an alcohol and an acid catalyst, wherein the feedstock comprises free fatty acids, glycerides, at least 10 wt % cellulosic material based on the dry weight of the feedstock, and at least 10 wt % proteins based on the dry weight of the feedstock; and (b) reacting the feedstock and the alcohol, at a temperature in the range of 140.degree. C. to 260.degree. C., and at a pressure that is sufficient to prevent boiling of the alcohol during the reaction to generate fatty acid alkyl esters, cleave the cellulosic material, shorten the proteins.
 16. The method of claim 15, wherein the water content of the combination before reaction is at least 3 wt % of the dry weight of the feedstock.
 17. The method of claim 15, further comprising adding a fatty acid alkyl ester to the combination before reacting.
 18. The method of claim 15, further comprising separating the resulting fatty acid alkyl esters from the resulting cleaved cellulosic material.
 19. The method of claim 18, further comprising fermenting the cleaved cellulosic material to produce ethanol.
 20. The method of claim 15, wherein the algal lipids are converted into free fatty acids using an acid catalyzed reaction at less than 140.degree. C.
 21. The method according to claim 15 wherein the pressure is less than 50 psi.
 22. The method of claim 15, wherein the acid catalyzed hydrolysis step breaks down algae cell walls and releases the algal lipids.
 23. The method of claim 22, further comprising adding methanol to the fatty acids to form fatty acid methyl esters (FAME).
 24. The method of claim 23, wherein the alcohol is in an amount from 50% to 320% molar excess of the contained oil in the feedstock.
 25. The method of claim 15, further comprising centrifuging, filtering or settling the suspension to form liquid and solid components.
 26. The method of claim 25, further comprising decanting the liquid component by a phase separation procedure to form a heavy phase and a light phase.
 27. The method of claim 26, wherein the heavy phase comprises water, glycerol, acid and methanol.
 28. The method of claim 25, wherein the light phase comprises FAME and free fatty acids (FFA).
 29. The method of claim 26, wherein the heavy phase is preheated by flashing to separate glycerol and acid from water and methanol.
 30. The method of claim 26, further comprising removing the glycerol and acid in a liquid bottoms stream.
 31. The method of claim 27, wherein the water and methanol are distilled to separate the methanol from the water.
 32. The method of claim 27, further comprising recycling the distilled methanol to react with free fatty acids.
 33. The method of claim 28, wherein the FFA and FAME are reacted with additional acid and methanol to complete the production of FAME from FFA. 